Microwave-induced localized heating of cnt filled polymer composites for enhanced inter-bead diffusive bonding of fused filament fabricated parts

Abstract

A microwave-induced heating of CNT filled (or coated) polymer composites for enhancing inter-bead diffusive bonding of fused filament fabricated parts. The technique incorporates microwave absorbing nanomaterials (carbon nanotubes (CNTs)) onto the surface or throughout the volume of 3D printer polymer filament to increase the inter-bead bond strength following a post microwave irradiation treatment and / or in-situ focused microwave beam during printing. The overall strength of the final 3D printed part will be dramatically increased and the isotropic mechanical properties of fused filament part will approach or exceed conventionally manufactured counterparts.

Description

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS[0001]This application claims priority to U.S. Patent Appl. Ser. No. 61 / 920,937, filed Dec. 26, 2014, entitled “Microwave-Induced Localized Heating Of CNT Filled Polymer Composites For Enhanced Inter-Bead Diffusion Of Fused Filament Fabricated Parts.” The foregoing patent application is hereby incorporated herein by reference in its entirety for all purposes.GOVERNMENT INTEREST[0002]This invention was made with government support under Grant No. Texas Tech University: CBET-1133250, NSF CBET NanoEHS, “Carbon nanotube detection in plants through microwave-induced heating.” The government has certain rights in the invention.FIELD OF INVENTION[0003]The present disclosure relates generally to microwave-induced heating of CNT filled (or coated) polymer composites for enhancing inter-bead diffusive bonding of fused filament fabricated parts. The present invention embodies a technique for incorporating microwave absorbing nanomaterials (carbon n...

AI Technical Summary

Benefits of technology

The present invention relates to a technique for improving mechanical properties of 3D printed parts by enhancing inter-bead diffusive bonding of fused filament fabricated parts. The technique involves incorporating microwave absorbing nanomaterials onto the surface or throughout the volume of polymer filaments used in 3D printing, and employing a cheap, rapid, and scalable post processing technique to greatly enhance mechanical properties. The invention provides a facile treatment process for improving the mechanical properties of 3D printed thermoplastic parts, and enables site-specific bonding of parts with focused microwave energy for superior control of mechanical properties and embedded electronics. Additionally, the invention enables the manufacture of embedded electronics, such as strain sensors, temperature sensors, touch sensors, electroluminescent indicators, and electromechanical actuators, by including site-specific nanomaterials segmented along the length of the printer filament.

Problems solved by technology

This process results in incomplete welding of the beads and subsequently reduced mechanical properties due to inter-bead delamination especially in loads applied perpendicularly to the bead or “road” alignment.

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